Packaging means and methods for reducing decomposition of particulate products during shipping and handling

ABSTRACT

The present invention relates to a means of packaging to reduce decomposition of particulate products, such as dry flake cereals that are often crushed, compacted, or pulverized during shipping and handling, by distributing the product across a multiplicity of structurally isolated cellular storage sections within the package.

CROSS-REFERENCE TO RELATED APPLICATIONS References Cited

U.S. Patent Documents 6,510,981 Jan. 28, 2003 Deering et al. 220/258.3 6,050,484 Apr. 18, 2000 Galomb 229/222. 5,851,069 Dec. 22, 1998 Davoren. 383/38. 5,251,808 Oct. 12, 1993 Rudd 229/101.2. 5,958,483 Sep. 28, 1999 Anders 426/112. 6,892,933 May 17, 2005 Sullivan 229122.33. 6,102,277 Aug. 15, 2000 Krapohl 229/101.2 6,814,234 Nov. 9, 2004 Lipper 206/459.5

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to means and methods of packaging to reduce decomposition of particulate products, such as dry flake breakfast cereals, that are often crushed, compacted, or pulverized during shipping and handling. This invention minimizes product decomposition by distributing the product into structurally isolated packaging cells.

2. Discussion of Background

Packaging of particulate products, such as dry flake breakfast cereals, and the like have not changed significantly in 25 years. This maybe due to the increased cost of manufacturing, distribution, and shipping but more likely due to the accepted business practice of “If it ain't (Sic) broke don't fix it.” that originated with government official Bert Lance in May 1977. In the past 5 years product manufacturers were motivated by club warehouse giants, like Wal-Mart and Costco, to reduce costs and manufacturers responded by increasing their product's package size as the only cost-effective means of reducing costs.

As a consequence of increasing the package size to hold more product the pressure on the product, at the bottom of the package, increased proportionally and, owing to this, so did product decomposition. This, over time and package movement, causes the product to settle and ultimately decompose into smaller and smaller granulated particulate that ultimately settles to the bottom of the packaging. In the case of edible product, such as flake cereal or shredded wheat, the percentage decomposition is considerable sometimes reducing the edible product by twenty percent or more—nobody wants to eat cereal with a texture like sand.

Manufacturer's often label their product with a disclaimer stating that the product is packaged by weight, not volume, probably owing to complaints precipitated by consumers feeling shortchanged. Although this decomposition is perceived as waste by the consumer a manufacturer might fallaciously argue “The consumer will maintain product loyalty as the decomposition is only cosmetic.” Studies have shown that product loyalty has its price and consumers will go to a competitor, who offers a similar product at a competitive price, which looks better, and has less waste.

BRIEF SUMMARY OF THE INVENTION

Accordingly with its major aspects already briefly recited, the present invention discloses packaging means to reduce decomposition of particulate products, such as dry flake breakfast cereals, often crushed, compacted, or pulverized during shipping and handling. The main emphasis of the invention is to minimize product decomposition into loose grains, similar to sand, caused by compaction or shifting due to the increased amount of product in larger packaging. Reduction in decomposition is accomplished by inserting sectional barriers between the product thereby emulating individual product packaging. This isolation constitutes product separation that reduces the forces exerted on the product and adjoining products. The sectional cell barriers can be made using the same material as the primary packaging making manufacturing a simple modification of the existing form. Insertion of product at manufacturing time is not changed, just reoriented, from the top of the packaging to the front, back, or sides and as such does not require major modification of packaging machinery. The consumer only has to open one perforated sectional cell compartment of the package to retrieve the product and there may be as many cell compartments as necessary to preserve the product. Package recognition by consumers is not compromised as externally the packaging and its artwork essentially remain the same.

Other advantages of this structurally cellular packaging concept are its ability to: size cellular sections as a function of product, accommodate individual serving sizes, accommodate existing sealed bag technology, increase shelf time owing to individual cellular section opening-closing, be implemented at low cost. Other features and their advantages will be apparent to those skilled in the art of particulate product packaging from a careful reading of the Detailed Description of Preferred Embodiments accompanied by the following drawings.

BRIEF DESCRIPTION OF THE DRAWINGS In the drawings,

FIG. 1 is a pictorial of particulate product packaging showing the package closed, as delivered to the consumer, according to a preferred embodiment of the present invention;

FIG. 2 shows a pictorial of particulate product packaging with the package open, ready for insertion of product, during production according to a preferred embodiment of the present invention and;

FIG. 3 shows cereal, contained in a sealed bag, as an exemplary particulate product ready for insertion into packaging according to a preferred embodiment of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

The present invention relates to a means of packaging particulate product, such as dry flake breakfast cereals, to reduce decomposition caused by product compaction during shipping and handling. This invention minimizes product decomposition by isolating product into cell structured compartments thereby reducing gravitational and frictional forces that cause product degradation.

Instead of having a single section house the product the invention partitions the packaging into several isolated cellular sections and thereby minimizes product interaction—reducing decomposition.

Only minor modifications in package structure are required maintaining product recognition and manufacturing methods in form, fit, and function while promoting simplicity of product access, increased shelf-life, and use by customer.

For simplicity and clarity in this description cereal will be used as an exemplary particulate product and it will be assumed that this is synonymous with any particulate product and the present invention would operate in the same fashion as described.

FIG. 1 is a pictorial of particulate product packaging showing the package closed, with a multiplicity of side cover sections 100 covering structurally isolated cells containing product, not shown, according to a preferred embodiment of the present invention. Access to the product, not shown but located under covers 100, is obtained by pulling tabs 110 that separate perforated cuttings 180. When selected perforations, 180, are punctured cover sections 100 are opened, but remain connected to the package via edge 190, and allow access to the product. All sections may be accessed simultaneously by opening sticky edge, 175, removing contact with the front, or back, (not shown) of the package 150. FIG. 1, 120 is by convention the top of the package and 130 is the bottom with 150 being the front, or back, (not shown) of the package containing graphics or text, 165.

There are, of course, numerous ways of implementing removable covers for the structurally isolated cells containing product other than perforated edges. These include sealants, hinges, pressure fittings and various other forms of interconnecting means. Therefore, the present invention is not limited to the embodiment shown, but includes any mechanism for removing a cell section cover, or cell section, from a package without departing from the spirit and scope of the present invention.

FIG. 2 shows a pictorial of particulate product, in this example cereal, packaging with the both sides, 255 and 250, of the package open, ready for insertion of cereal, during production according to a preferred embodiment of the present invention. FIG. 2, 260, indicates the direction of closure for side, 255, with direction of travel, 270, for closure of side, 250. Note that during insertion of cereal only one side, 255 or 250, at a time would be open if the cereal was not individually packaged as shown in FIG. 3, 350.

FIG. 3 shows cereal, 350, contained in a sealed bag ready for insertion into packaging cell, 380, structurally isolated by separator, 375, according to a preferred embodiment of the present invention.

Although FIGS. 1, 2, and 3 describe the basic configuration of the invention they are only exemplary illustrations and omission of package, dimensions, shape, products to be packaged, or the advantages of using the invention to reduce costs, increase product stability, and sales are not intended as restrictions or limitations.

It will be readily apparent to those skilled in the art of packaging from reading the foregoing that many substitutions and modifications may be made to the preferred embodiments described without departing from the spirit and scope of the present invention. 

1. A means of packaging and distribution of particulate products into structurally isolated storage sections that reduce product decomposition, compacting, crushing, shifting, and pulverizing with said means being comprised of: Isolated cellular compartments; with individually partitioned removable cell covers, opening tabs, and flexible sides with adhesive sealant edges for inserting or removing product with covers, compartments, sides, and partitions being fabricated of paper, cardboard, plastic, metallic materials, or composites.
 2. The means as recited in claim 1, further comprising sealed bags, boxes or other containment assemblies containing product to be inserted into structurally isolated storage sections that reduces product decomposition, compacting, crushing, and shifting.
 3. The means as recited in claim 1, wherein said isolated cellular compartments being comprised of formed, molded, or assembled components and materials fitted into or structurally part of cellular compartments that provide for structurally isolating product to reduce decomposition, compacting, crushing, and shifting.
 4. The means as recited in claim 1, further comprising individually partitioned removable cell covers being able to be individually separated by means of scoring, indentation, serration, notching, stamping, or cutting to remove or displace said cover for the purpose of removing or replacing product.
 5. The means as recited in claim 1, wherein said flexible sides with adhesive sealant edges for inserting or removing product adhesive sealant may permanently seal, or be resealable, of for the purpose of loading, unloading or replacing product.
 6. The means as recited in claim 1, further comprising resizing all or individual sections, partitions, cells, or sides to reconfigure packaging to simultaneously accommodate different quantities or different products in the same package and insure product freshness if so desired or required.
 7. The means as recited in claim 1, wherein said particulate product is cereal packaged to reduce decomposition, compacting, crushing, shifting, pulverizing, and distribution costs while increasing product life.
 8. The means as recited in claim 1, wherein the form, fit and function of product packaging is maintained insuring that product recognition, advertising, handling, and distribution is not affected.
 9. The means as recited in claim 1, wherein the insertion or removal of product is from the sides, front, or rear of the package, as opposed to the conventional top or bottom, during production or use.
 10. The means as recited in claim 1 herein the inclusion of the isolated cellular compartments; with individually partitioned removable cell covers, opening tabs, and flexible sides with adhesive sealant edges for inserting or removing product with covers, compartments, sides, and partitions being fabricated of paper, cardboard, plastic, metallic materials, or composites does not significantly reduce the amount of product enclosed or increase the total package weight. 